Multiple-component tampon applicator

ABSTRACT

There is provided a multiple-component tampon applicator formed from at least three separate components. A fingergrip having a reduced cross-section as compared to that of the barrel may be formed such that it is a separate component or is integrally formed with a barrel component. The reduced cross-section fingergrip provides exceptional grippability to the user. The multiple components may be formed from materials including, for example, biopolymer including starches and proteins, cardboard, heat shrink plastic, paper slurry, plastic, plastic tubing, pulp slurry, pulp-molded paper, or any combinations thereof. Prior to assembly of the applicator and prior to loading the barrel component with an absorbent pledget, petals may be formed on the insertion end of the barrel using existing processes and equipment. Alternatively, a separate insertion tip component having petals may be formed. This separate component may then be connected to the barrel component either before or after an absorbent pledget is loaded into the barrel component.

CROSS REFERENCE TO RELATED PATENT APPLICATIONS

This application is a divisional of U.S. patent application Ser. No.11/137,809, filed on May 25, 2005 entitled “Multiple-Component TamponApplicator,” now pending, which claims the benefit of U.S. patentapplication Ser. No. 10/081,528, filed on Feb. 22, 2002, and issued onAug. 8, 2005, as U.S. Pat. No. 6,923,789. The aforementionedapplications are herein incorporated by reference in their entirety.

BACKGROUND OF THE INVENTION

1. Field of the Invention

The present invention relates to an insertion device, such as acatamenial tampon applicator. More particularly, the present inventionrelates to a multiple-component tampon applicator formed from at leastthree distinct and separate components.

2. Description of Related Art

The majority of commercial tampon applicators are of approximatelyuniform cross-section and are formed from only two components, namely abarrel and a plunger. The fingergrip, if any, is formed as an integralpart of the barrel component. Some applicators have a fingergrip and aplunger of a cross-sectional area reduced from that of the applicatorbarrel. This feature has been found not only to render the tamponapplicator more grippable, but it is also more aesthetically preferred.

For current reduced cross-sectional area fingergrip tampon applicators,the tampon pledget must be loaded into the insertion end of theapplicator due to the smaller opening at the fingergrip end. Thus, thesetampons are restricted to top or insertion end loading. This requiresthe petals of the applicator, if any, to be post-formed to their finalshape after the pledget has been loaded. Post-forming of petals requiresthe material to be plasticized. Typically, plastic petals areplasticized by heat and are easily shaped by the use of an externalforming die.

On the other hand, cardboard petals are more difficult to plasticize andrequire the additional use of an internal mandrel. Usual methods involveheating the tip to volatize the water (either existing or supplementalmoisture), and then forcing the petal into shape using an internalmandrel in conjunction with the external die. The internal mandrel has across-sectional area that is approximately the same as the barrel'sinterior, and consequently would not be able to enter through a reducedcross-sectional fingergrip area. Therefore, the necessity of theinternal mandrel to shape the petal tip has thus far precluded themanufacture of a reduced cross-sectional fingergrip area on a cardboardapplicator.

Therefore, there is a need for a tampon applicator, and morespecifically a cardboard applicator, that can be manufactured such thatpetal tips can be pre-formed or integrated on the insertion end of theapplicator barrel, prior to loading an absorbent pledget, using existingmanufacturing processes and equipment.

SUMMARY OF THE INVENTION

It is an object of the present invention to provide a tampon applicatorthat is assembled from at least three distinct and separate components.

It is another object of the present invention to provide such a tamponapplicator that has a barrel formed from cardboard.

It is still another object of the present invention to provide such atampon applicator having a fingergrip with a reduced cross-sectionalarea compared to that of the applicator barrel.

It is a further object of the present invention to provide such a tamponapplicator having petals at the insertion end of the cardboard barrelprior to loading the barrel with an absorbent pledget.

It is still a further object of the present invention to provide such atampon applicator in which the petals are pre-formed using existingprocesses and equipment.

It is yet a further object of the present invention to provide such atampon applicator in which the petals are formed on a separate anddistinct insertion tip component that may be connected to a separatebarrel component either before or after a pledget is loaded into thebarrel component.

It is still yet a further object of the present invention to providesuch a tampon applicator that prior to assembly of the applicator, andprior to loading the barrel component with an absorbent pledget, petalsmay be formed on the insertion end of the barrel using existingprocesses and equipment.

These and other objects of the present invention will be appreciatedfrom a multiple-component tampon applicator formed from at least threeseparate and distinct components. A separate insertion tip componenthaving petals may be formed. This separate component may then beconnected to the barrel component either before or after an absorbentpledget is loaded into the barrel component. Also, a fingergrip may beformed as a separate component or it may be integrally formed with thebarrel.

The multiple components may be formed from materials including, forexample, plastic, cardboard, paper slurry, pulp slurry, pulp moldedpaper, heat shrink plastic, plastic tubing, biopolymers includingcarbohydrates and proteins, or any combinations thereof.

DESCRIPTION OF THE DRAWINGS

FIG. 1 is an exploded view of a multiple-component applicator havingthree components that form the tampon applicator of the presentinvention;

FIG. 2 is an exploded view of a multiple-component applicator havingfour components that form the tampon applicator of the presentinvention;

FIG. 3 is an exploded view of a three-component applicator of thepresent invention where the barrel component includes the fingergrip;

FIG. 4 is a perspective view of an assembled three-piece tamponapplicator of FIG. 1;

FIG. 5 is a perspective view of a fingergrip component of the tamponapplicator of FIG. 1;

FIG. 6 is a perspective view of a fingergrip component according toanother embodiment of the present invention;

FIG. 7 is a perspective view of a three-piece applicator according toyet another embodiment of the present invention;

FIG. 8 is a perspective view of several embodiments of fingergripcomponents having various gripping structures according to the presentinvention;

FIG. 9 is a perspective view of a fingergrip component according toanother embodiment of the present invention;

FIG. 10 is a perspective view of a fingergrip component according toanother embodiment of the present invention;

FIG. 11 is a perspective view of a fingergrip component according toanother embodiment of the present invention;

FIG. 12 is a perspective view of a multiple-component applicator havingthree components that form one embodiment of a tampon applicator of thepresent invention;

FIG. 13 is a perspective view of the fingergrip and barrel components ofFIG. 12 in a heated former; and

FIG. 14 is a perspective view of a multiple-component applicator withthe barrel and fingergrip formed in the heated former of FIG. 13.

DETAILED DESCRIPTION OF THE INVENTION

Referring to the drawings and in particular FIG. 1, a first embodimentof a multiple-component tampon applicator of the present invention isrepresented generally by reference numeral 10. One distinguishingfeature of this applicator 10 is that instead of being formed from twocomponents, namely, a barrel and a plunger, it is formed from threedistinct components. In a preferred aspect of this first embodiment, thethree distinct components are barrel 12, plunger 14, and fingergrip orfingergrip component 16.

The barrel 12 retains its approximately uniform cross-section, thusallowing petals 18 to be formed prior to pledget insertion. The petals18 can be formed with the assistance of an internal mandrel, if desired.

Referring to FIG. 2, a second embodiment of the multiple-componenttampon applicator according to the present invention is depicted. Thisapplicator 10 is formed from four distinct components. Again, as apreferred aspect of this second embodiment, the preferred components arebarrel 12, plunger 14, fingergrip 16, and insertion tip 19. Petals 18are formed on insertion tip 19. As such, an absorbent pledget may beloaded into barrel 12 either before or after insertion tip 19 isconnected to barrel 12.

Referring to FIG. 3, a third embodiment of the multiple-componentapplicator of the present invention is shown. This applicator 10 isformed from at least three distinct components, namely, barrel 12,plunger 14, and insertion tip 19. Barrel 12 has a forward end 21. Inthis embodiment, fingergrip 16 is integrally formed as part of barrel12. An absorbent pledget may be loaded into barrel 12 through forwardend 21, prior to connecting insertion tip 19 to the barrel.

Barrel 12 of the multiple-component applicator 10 of the presentinvention may be formed from any suitable material. Suitable materialsfor forming barrel 12 include, for example, biopolymer, cardboard, heatshrink plastic, paper slurry, plastic, plastic tubing, pulp slurry,pulp-molded paper, or any combinations thereof. Preferably, barrel 12 isformed from cardboard. Barrel 12 may be formed from spiral wound orconvolutely wound cardboard.

Any individual component that forms the multiple-component applicator,and especially barrel 12, may be internally and/or externally coatedwith any suitable material to enhance its strength and/or reduce surfacefriction. Suitable coatings include, for example, cellophane, cellulose,epoxy, lacquer, nitrocellulose, nylon, plastic, polyester, polylactide,polyolefin, polyvinyl alcohol, polyvinyl chloride, silicone, wax, or anycombinations thereof. It should also be understood that barrel 12, whiledepicted as a single component, may be formed from one or morecomponents, such that when assembled, the one or more components formbarrel 12.

Plunger 14 may be formed from any suitable material. Suitable materialsfor forming plunger 14 include, for example, biopolymer, cardboard, heatshrink plastic, paper slurry, plastic, plastic tubing, pulp slurry,pulp-molded paper, or any combinations thereof. Preferably, plunger 14is formed from cardboard.

Referring to FIGS. 1 and 2, fingergrip 16, as a separate component,provides a way to create an applicator having a cardboard barrel withpre-formed petals and, perhaps, a reduced cross-sectional fingergriparea with an accompanying reduced cross-section plunger 14. Fingergrip16 has two distinct ends, barrel or forward end 20 having a diameterapproximately equal to that of barrel 12, and plunger or rearward end 22having a diameter slightly larger than that of plunger 14. Fingergrip 16also has channel 26, which extends axially through the entire length ofthe fingergrip. Channel 26 has a cross-sectional area slightly largerthan that of plunger 14 so as to accommodate the plunger during assemblyof applicator 10. The pledget (not shown) is loaded into barrel 12through fingergrip or rearward end 24 of the barrel. Petals 18, if any,on barrel 12 have been pre-formed into their final shape, as in FIG. 1.

As shown in FIG. 2, when insertion tip 19 and fingergrip 16 are formedas separate components, an absorbent pledget (not shown) may be loadedeither through forward end 21 or barrel rearward end 24 of barrel 12.

Referring to FIG. 3, when insertion tip 19 is formed as a distinctcomponent, it also allows barrel 12 and fingergrip 16 to be formed asone component. With this configuration, an absorbent pledget may beloaded into barrel 12 through forward end 21, prior to assembling themultiple-component applicator.

By way of example, FIG. 4 shows the three-component applicator of FIG. 1assembled. Once an absorbent pledget (not shown) is loaded into barrel12, barrel forward end 20 of fingergrip 16 is connected to barrel 12 atbarrel rearward end 24. Plunger 14 is then inserted into fingergripplunger end 22 through channel 26. Alternately, plunger 14 may be loadedinto channel 26 of fingergrip 16 prior to the fingergrip being connectedto barrel 12. Fingergrip 16 may be secured permanently to barrel 12 byany conventional method. Preferably, fingergrip 16 is connected tobarrel 12 with an adhesive. Outer edge 25 of fingergrip 16 may be ofsuch a size that it creates a continuous surface flush with the outeredge of barrel 12.

It should be understood that the multiple-component tampon applicatorsdepicted in FIGS. 2 and 3 may also be assembled according to the samebasic tenets set forth for assembling the three-component applicator ofFIG. 1. One distinguishing feature of the applicator of FIG. 2 withrespect to assembly, is that the absorbent pledget may be loaded intobarrel 12 either through forward end 21 or barrel rearward end 24.Therefore, the order in which the components are assembled may depend onwhich end of barrel 12 the pledget is loaded. A distinguishing featureof the applicator of FIG. 3, with respect to assembly, is that barrel 12and fingergrip 16 are formed as one component, therefore, the absorbentpledget must be loaded into barrel 12 through forward end 21, prior toassembling insertion tip 19 with barrel 12.

It should also be understood that each component of the tamponapplicator set forth above may be formed from one or more individualparts or sections (i.e. barrel 12, plunger 14, fingergrip 16 and/orinsertion tip 19 may be formed from one or more individual parts orsections that are connected to form the component). In addition, itshould be understood that while each applicator component is shown aboveas being discrete and separate from each other, any two or more of thecomponents may be integrally formed and then assembled with the one ormore separate components. By way of example, the insertion tip 19, thebarrel 12, the fingergrip 16, and/or the plunger 14 may be integrallyformed, in any combination. In addition, any component that is made upfrom two or more parts or sections, as set forth above, may be connectedto form that component, prior to connecting with any other individualcomponent to form an assembled applicator 10. However, the overallapplicator will, nonetheless, have at least three components.

Fingergrip 16 can be formed from any suitable moldable material.Suitable moldable materials include, for example, biopolymer, cardboard,heat shrink plastic, paper slurry, plastic, plastic tubing, pulp slurry,pulp-molded paper, or any combinations thereof. In a preferredembodiment of the present invention, fingergrip 16 is formed from pulpmolded paper.

FIG. 5 is another embodiment of the present invention. Fingergrip 16 isformed with a connector ring 32 on barrel forward end 20. Connector ring32 has a diameter slightly larger than the internal diameter of barrel12 so that fingergrip 16 can be connected and secured to barrel 12 byinterference fit.

FIG. 6 is another embodiment of the present invention. Connector ring 32may be formed with one or more tabs, ridges and/or slots 34. One or moretabs, ridges and/or slots 34 can interlock with corresponding tabs,ridges and/or slots (not shown) formed on the inner surface of barrel12, thus securing fingergrip 16 to barrel 12. The one or more tabs,ridges and or slots may be formed on external and/or internal surfaces.

FIG. 7 is another embodiment of the present invention. In thisembodiment, fingergrip 16 is formed from a heat-shrinkable material 36that has an initial diameter larger than the outer diameter of barrel12, and shrinks to a diameter at least as small as plunger 14.Heat-shrinkable material 36 at barrel end 20 is shrunk to fit theoutside of barrel 12 snugly. The union between heat-shrinkable material36 and barrel 12 can be reinforced with an adhesive. Plunger or rearwardend 22 of fingergrip 16 is shrunk so that it is just larger than theoutside diameter of plunger 14.

The fingergrip 16 may be formed with any number and/or configuration ofgripping structures, to further enhance the applicator's grippability.Fingergrip 16 may be smooth or, more preferably, may include one or morepatterned or textured structures extending above and/or below thesurface of the fingergrip.

The gripping structures may include, for example, one or more abrasivematerials, embossments, grooves, high wet coefficient of frictionmaterials, lances, pressure sensitive adhesives, protuberances, slits,treads, or any combinations thereof. In addition, the grippingstructures may be formed in any shape, including, for example, arc,circle, concave, cone, convex, diamond, line, oval, polygon, rectangle,rib, square, triangle, or any combinations thereof.

Referring to FIG. 8, by way of example, several different fingergripembodiments having various gripping structures are depicted. FIG. 8Adepicts fingergrip 16 with one or more bands 38 circumferentiallydisposed around fingergrip rearward end 22. FIG. 8B depicts fingergrip16 with one or more dot-like structures 40 disposed circumferentiallyaround fingergrip rearward end 22. FIG. 8C depicts fingergrip 16 withone or more circular structures 42 disposed circumferentially aroundfingergrip rearward end 22. FIG. 8D depicts fingergrip 16 with two ormore wavy bands 44 disposed circumferentially around fingergrip rearwardend 22.

It should be understood that the gripping structures may be arrangedcircumferentially around fingergrip 16 in any pattern suitable forforming a gripping area. For example, the gripping structures can form adistinct pattern, such as, rows, columns or may be formed intermittentlywith breaks in structure or in any random order or pattern.

FIG. 9 is another embodiment of the present invention. In thisembodiment, fingergrip rearward end 22 may be formed with acircumferentially flared or ridge-like structure end 46, to furtherenhance the gripping characteristics of the applicator.

FIG. 10 is another embodiment of the present invention. In thisembodiment, fingergrip rearward end 22 is formed with a stepped taper tofurther enhance the gripping characteristics of the applicator.

FIG. 11 is another embodiment of the present invention. In thisembodiment, fingergrip rearward end 22 may be formed with a knob-likestructure 48 to further enhance the gripping characteristics of theapplicator.

Any combinations of the features depicted in FIGS. 8 through 11, anddescribed above, are possible as well. In addition, the grippingstructures could be raised, depressed, or any combination thereof, withrespect to the surface of the fingergrip area. The gripping structurescan be formed in any shape, in any number, and in any pattern orconfiguration suitable for forming an enhanced gripping area onfingergrip 16. As such, it should be clear that the present invention isin no way limited by those features depicted or described above.

It is also understood that the cross-section of barrel 12, plunger 14,fingergrip 16 and insertion tip 19 can be circular, oval, polygonal orelliptical. Also, insertion tip 19 can be tapered, elliptical,dome-shaped or flat. Barrel 12 can be straight, tapered, or curvilinearalong its length.

Referring to FIGS. 12 through 14, a method of assembling a multiplecomponent tampon according to another embodiment of the presentinvention is depicted. Applicator 10 has independent or discrete barrel12, plunger 14 and fingergrip 16. To assemble the components, adhesive50 is applied to the fingergrip barrel end 20. As depicted in FIG. 13,fingergrip 16 is inserted into cavity 62 of heated shaper 64. Mandrel 60is inserted into fingergrip 16 housed in cavity 62. Barrel 12 isinserted over mandrel 60. The barrel 12 and fingergrip 16 are allowed toremain in position in heated shaper 64 for about 1 to 20 seconds andmore preferably 5 to 10 seconds.

Referring to FIG. 14, when removed from the mandrel 60 and heated shaper64, the fingergrip 16 is connected to barrel 12 at tapered rearward end66. Plunger 14 may then be inserted into fingergrip 16.

The foregoing specification and drawings are merely illustrative of thepresent invention and are not intended to limit the invention to thedisclosed embodiments. Variations and changes, which are obvious to oneskilled in the art are intended to be within the scope and nature of thepresent invention, which is defined in the appended claims.

1. A method of making an applicator having four separate componentscomprising the steps of: (a) forming a barrel having a forward end and arearward end; (b) forming a fingergrip having a forward end, a rearwardend, and an axially extending channel between said forward end and saidrearward end; (c) forming an insertion tip having a forward insertionend and a rearward end; (d) forming a plunger having a forward end; (e)connecting said forward end of said fingergrip with said rearward end ofsaid barrel; (f) connecting said rearward end of said insertion tip tosaid forward end of said barrel; and (g) inserting said forward end ofsaid plunger into said channel of said fingergrip.
 2. The method ofclaim 1, wherein one or more of said four separate components are formedfrom a material selected from the group consisting of biopolymer,cardboard, heat shrink plastic, paper slurry, plastic, plastic tubing,pulp slurry, pulp-molded paper, and any combinations thereof.
 3. Themethod of claim 1, wherein two or more of said four separate componentsare formed from a material selected from the group consisting ofbiopolymer, cardboard, heat shrink plastic, paper slurry, plastic,plastic tubing, pulp slurry, pulp-molded paper, and any combinationsthereof.
 4. The method of claim 1, wherein three or more of said fourseparate components are formed from a material selected from the groupconsisting of biopolymer, cardboard, heat shrink plastic, paper slurry,plastic, plastic tubing, pulp slurry, pulp-molded paper, and anycombinations thereof.
 5. The method of claim 1, wherein at least one ofsaid four separate components is coated with a material selected fromthe group consisting of cellophane, cellulose, epoxy, lacquer,nitrocellulose, nylon, plastic, polyester, polylactide, polyolefin,polyvinyl alcohol, polyvinyl chloride, silicone, wax, and anycombinations thereof.
 6. The method of claim 1, wherein said forwardinsertion end of said insertion tip comprises three to eight petals. 7.The applicator of claim 1, wherein said fingergrip further comprises atleast one gripping structure.
 8. The applicator of claim 7, wherein saidat least one gripping structure is circumferentially disposed aroundsaid fingergrip.
 9. The applicator of claim 7, wherein said at least onegripping structure is selected from the group consisting of one or moreabrasive materials, embossments, grooves, high wet coefficient offriction materials, lances, pressure sensitive adhesives, protuberances,slits, treads, and any combinations thereof.
 10. The applicator of claim7, wherein said at least one gripping structure is formed in a shapeselected from the group consisting of arc, circle, concave, cone,convex, diamond, line, oval, polygon, rectangle, rib, square, triangle,and any combinations thereof.
 11. The applicator of claim 7, whereinsaid at least one gripping structure is raised above, depressed below,or a combination thereof, a surface of said barrel.
 12. The method ofclaim 1, wherein said forward end of said fingergrip has an externalcross-sectional area slightly larger than that of an internalcross-sectional area of said rearward end of said barrel, and whereinsaid fingergrip and said barrel are connectably secured by interferencefit.
 13. The method of claim 1, wherein said forward end of saidfingergrip has an internal cross-sectional area slightly smaller than anexternal cross-sectional area of said rearward end of said barrel, andwherein said fingergrip and said barrel are connectably secured byinterference fit.
 14. The method of claim 1, wherein said forward barrelend of said fingergrip further comprises one or more external tabs,ridges, slots, or any combination thereof, for securably connecting saidfingergrip to said barrel.
 15. The method of claim 1, wherein saidforward barrel end of said fingergrip further comprises one or moreinternal tabs, ridges, slots, or any combination thereof, for securablyconnecting said fingergrip to said barrel.
 16. The method of claim 1,wherein said rearward end of said barrel further comprises one or moreexternal tabs, ridges, slots, or a combination thereof, for securablyconnecting said barrel to said fingergrip.
 17. The method of claim 1,wherein said rearward end of said barrel further comprises one or moreinternal tabs, ridges, slots, or a combination thereof, for securablyconnecting said barrel to said fingergrip.
 18. The method of claim 1,wherein said forward end of said barrel further comprises one or moretabs, ridges, slots, or any combination thereof, for securablyconnecting said barrel to said insertion tip.
 19. The method of claim 1,wherein said rearward end of said insertion tip further comprises one ormore tabs, ridges, slots, or any combination thereof, for securablyconnecting said insertion tip to said barrel.
 20. The method of claim 1,wherein said fingergrip is formed from heat-shrinkable material having adiameter larger than a diameter of said barrel, and wherein saidheat-shrinkable material is shrunk to securably fit over an outsidesurface of said barrel.
 21. The method of claim 20, wherein saidheat-shrinkable material is further shrunk at said rearward end of saidfingergrip to form a reduced cross-sectional area.